ggCinharacteristics ol Dry- ype

Tr a n s fo r me r I nsu l a t i o n at

High Temperature
H. C. STEWART

L. C. WHITMAN

MEMBER AIFE

MEMBER AIEE

*NSULATIONS used in class B insu-

Elated dry-type transformers consist of

such materials as glass yarn and sheet
asbestos and even cellulose in combination with a heat-resistant varnish. The
life characteristics of such insulation with
particular reference to the gas medium in
which the material is required to function
is discussed in this paper. Further data
on the aging of this insulation will be
available when the co-operative aging
tests that are being conducted under the
supervision of the working group of the
AIEE transformer committee are completed.
The life of any material is dependent
not only upon its temperature but also
upon the medium in which that temperature is attained. There is a fundamental
difference in the life of insulation containing organic materials operating in an
insulating liquid or in a gas medium. In
the former instance, the material ages
mechanically, but by virtue of liquid
absorption, it maintains its electrical
strength to a remarkable degree if undisturbed by vibration. In the latter case
where the material operates in a gas
medium, there is not only a reduction in
the mechanical strength but in the electrical strength as well. This latter situa-

tion results from the aging of the varnish

impregnant used to impart high dielectric and mechanical qualities to the base
material. In the process of deteriora-

originally designed into such equipment.

Such loss renders the apparatus less likely
to withstand the more severe operating
conditions, such as lightning, switching
surges, and short circuits.
Recognition of these conditions leads
to the conclusion that dielectric strength
is a dominant factor in evaluating the life
of insulations aged in a gas medium. On
this premise, a percentage of the initial
dielectric strength, at operating temperature, has beenl chosen as the criterion.
The value of this percentage selected as
indicative of insulation life is arbitrary.
An approach to 50 per cent reduction is
increasingly dangerous and may well

represent the end of life. The major

part of these data, therefore, is predicated on the end of life occurring at a
point where the dielectric strength has
diminished to one-half of its initial value
at operating temperature.
Data are presented on both class A and
class B insulations subjected to temperatures in excess of presently-established
operating levels. From these data, extrapolation can be made to indicate anticipated life at normal operating temperature. The results shown here indicate
the maximum life which can be expected
from insulations when maintained continuously at a given operating temperature. Intermittent operation may introduce other conditions, such as moisture

Paper 48-289, trecoamdmaenpdeodbdythe AIBE transhas a much lower dielectric strength.

nical program committee for presentation at the
AIEE Midwest general meeting, Milwaukee,
Engineers are conscious of the fact that October 18-22, 1948. Manuscript submitted Wis.,
July
the reduction in dielectric strength Of 29, 1948; made available for printing September
electric apparatus can be serious* since
C. STEWART and L. C. WHITMAN are both with
r it
encroaches upon the factors ~~~~~~H.
of rsafety
the General Electric Company, Pittsfield, Mass,
tion, the varnish is replaced by air which

1600

-Stewavrt, Whitman-Transformer Insulation

absorption, contamination of the operat-

ing medium, and so forth, which will be a

factor in further reducing the life beyond

thatFinally,
indicated
by these data.
these data and arbitrarily

as-

sumed load cycles are used to estimate the

life of a dry-type transformer.

Material Investigated

The varnish impregnant used is a heat-

resisting type and is specifically referred

to hereafter as a high-temperature phe-

nolic varnish.

The following list is a specification of

the materials tested.

1. Commercial grade of sheet asbestos.

Thickness-15 mils.
nolic varnish.
Cooling medium-air at atmospheric
pressure.

2. Commercial grade of sheet asbestos.

Thickness-15 mils.
Impregnant-high-temperature
phe-

nolic varnish.

gauge pressure.
Fiber
glass yarn.
3
Thickness-20 mils.
Impregnant-high-temperature
nolic varnish.

Cooling

medium-air

at

phe-

atmospheric

Electricalgrade of black-varnishedcam
Thickness-7 mils.
Impregnant-no additional.
Cooling medium-air at atmospheric
pressure.

5. Electrical grade of kraft paper.

(Grade used inmils.

insulating cylinder)
Thickness-4
pheImpregnant-high-temperature
nolic varnish.
Cooling medium-air at atmospheric
pressure.
The curing time and temperature for
the sheet-asbestos and glass-yarn test
pieces are those recommended by the
manufacturer for curing the high-temperahnlc ans ue.I tees
of the kraft-paper test pieces, the curing
was accomplished by a redutieton of
temperature with an increase in duration
of cure to prevent deterioration of this
class A materila.

AIFE TRANSACTIONS

THICKNESS
2 (15 MIL)l
APPLICATION
LAYER INSULATION.
-

400

G~~~RADE

COMMERCIAL
I~~~MPREGNANT- HIGH TEMPERATURE PHENOLIC VARNISH
IVBREAKDOWN CRITERION I MINUTE TEST IN AIR AT ATMOSPHERIC
PRESSURE

|l ll lX

3.300

.1

UJ 200
a.
0

100

or

Figure 1.

Component parts of insulation life test piece

50

150

100

200

250

TEMPERATURE IN DEGREES CENTIGRADE

300

Figure 4. Initial dielectric strength asbestos

6. Visual ilispection of test piece for check

These are representative of sonic of the

class A and class B transformer insulations used as winding layer material, wire
covering, and insulating cylinders.
'hile only a few of the possible coliibinations were tested, they are believed to be a
fair representation of the insulations used
in dry-type transformers and other airinsulated apparatus.

These requirements are realized in a

practical sense in the test piece used and
described in the following.

Choice of Test Pieces

Details of Test Piece and Testing

The physical arrangemenit of the test

material was selected to satisfy the following conditions:
1. Use of material in custoniary form.
2. Convenient and accurate measuremeut
and control of the temperature of the test
piece.
3. Provision for applying the dielectric test
to the entire test piece.
4. Temperature gradients in test piece
comparable to those enicouiitcred ill practice.
5. Inclusion of oxidationi effects oni tie test
piece by exposure to normal amnbient conditions.

sheets

oni ilchanlical effects, such as crazing or

crackiiig

could be treated and

t. A stricture
as a uniitthat
without daniger of dantiage
handledI
to the iasul .tion.

Technique

The heat source consisted of a 2-inch

diameter metal tube housing a calrodtype of heating unit, Figure 1. Unifori
heat conduction from the heating unit to
the tube was facilitated by a magnesium
oxide filling,
Temperatures of the inner surface of
the insulation were obtained from thermocouples brazed at intervals along the tube.
Temperatures of the outer surface of the
. ...
insulation were measured with thermocouples brazed to the narrow external
electrodes which cover the insulation
areas under test, Figure 2. Outer ther-

Figure 2. Partial and complete assembly of insulation life test piece

Figure 3 (below). Insulation life test piece using glass-covered wire

niocouples, usually greater in number,

owere
located directly
over the tube
weelctd
irtyovrhe
ub

thermocouples, so that it was possible to

plot temperature gradients parallel with
the inner and the outer surfaces. Precautions were taken in every instance to
see that thennocouple leads did not conduct heat from the thermocouple junction, thereby affecting the temperature
accuracy. This was accomplished by
associating at least six inches of the
thennocouple leads with the junction
temperature. The complete assemblies
were supported horizontally with thermocouples along the upper, or "12 o'clock,"
surface. Figures 1 and 2 show partial
and complete assemblies of the test piece.
The number of turns of insulation
wound on the tube was determined by
the dielectric strength of the material.
Insulation thickness was selected so that
the voltage was sufficient to minimize the
erratic breakdown behavior of small spac-

ings. Usually this resulted in a minimum

of 2,000 volts and a maximum of 4,()00

Figure 5. Summary of initial dielectric strength in air at atmospheric

pressure
- l l
l
l
l
l

,1 600

l2
12001

KV/SEC RATE OF RISE

I MINUTE TESTS

1/2.

-9. >>e<

0o FBER GLASS

t
l

NOTE;

ASBESTOS & KRAFT

PAPER SHEETS AND FIBER

YARNll|GLASS YARN ARE IMPREG-

> | l l { | 5 ~~~NATED WITH

2 1 8L4ce1

| +s+,

HIGH TEMP-|
ERAURE PHENOLIC VARNISH|

40

1948, VOLUME 67

150
100
200
250
TEMPERATURE IN DEGREES CENTIGRADE

50

Ste-wart, Whitman-Transformer Insulation

300

1601

volts where the 50 per cent criterion is

used.
Dielectric tests were applied at periodic
intervals between the tube and each outer
electrode with temperature maintained
continuously.
In addition to sheet material representative of layer insulation, glass-fiber yarn
was used as turn insulation on copper
wire. The insulated wire was wound on a
tube prepared in a manner similar to that
used in the assembly of test pieces with
sheet insulation. Outer electrodes were
fastened over the insulated wire. The
THICKNESS - 2 (IS MIL)
APPLICATION - LAYER INSULATION
w
GRADE - COMMERCIAL
aIVMPREGNANT - HIGH TEMPERATURE PHENOLlC

z9201960

"
w
x

~IDa

8C

operation. The complete assembly received the varnish impregnation under

vacuum.
Criterion of Life of Insulation
Operated in a Gas
This paper proposes that the end of expected life of insulation when operated
in a gas medium be considered as reached
when the dielectric strength (referred to
on figures as initial hot dielectric strength)
has decreased to 50 per cent of the initial
value with a given temperature maintained. This is an entirely arbitrary
selection based on such general considerations as initial insulation level of airinsulated apparatus; exposure of this
apparatus to transient voltages as affected
by usual location and application; and of

TEMP.
AVG. INS.
TEMP.

-.

Tb

ELECTRODE
TTE MP.

F-

6C

rise of 1/2 kv per second as recommended

by American Society for Testing Materials Standards.' All initial breakdown
tests were reduced to a volts-per-mil
basis, using the average of ten measured
thicknesses for each test piece.
Method of measuring thickness of
insulation is described in American
Society for Testing Materials Standards2
except that in case of turn insulation,
standard machinist's micrometers with
1/4-inch diameter anvils were used.
Typical data for asbestos are shown on
Figure 4. Composite curve, Figure 5,
covers all material tested.
The possible advantage of the momentary test is that corona is minimized.
The disadvantage is that it is not as
searching a test as the 1-minute test and
does not give opportunity for thermal

...

a-

5C.Watts Per
5

I-TTHERMOCOUPLE

THERMOCOUPLES

HEATER

~THERMOCOUPLES

MUETA

DRO TH OUG

POSITION

rF

Number of Layers of Sheet Asbestos Impregnated with

DE DMandrel

6~Sq.in.
OUTER

ELECTRODES

OUTE ELCTOD

1.25.

Temp.
00

High-Te merature Phenolic Varnish

2 Layers (0.0352)
00
00

Drop

Mul

3 Layers (0.0525) 4 Layers (0.0692)

00
00Cc00

Drop

Figur 7. herma dros thrugh iber lass

yarn ncuum coppterwireahight-

copper,conductor was grounded to the

tube so that dielectric tests could be made
between the outer electrodes and the
copper conductor. Figure 3 shows a
complete test piece.

lc-arnishcoper
yhe
kraft p-apers
The sheet
asbestos andwimricws
were preimpregnated but cured only to a
tacky state before being wound on the

Mul

0 Per

mul

00 Per

Watt Per
in.2 Per
in.

Deemnto

...

fIita

ilcrc

DESIRED TEMPERATURE

THERMOCOUPLE

Drop

Avg.

i.60 ..i..i.5....0.327..i.7.0....0.324....24.0....0.345.... .0.332.....262

..i.
5.6....0.443...23.0....0.438. ..32. 0....0.463.... .0.448.....243
.0.579.....236
....20.5...0.582...29.8....0.568...40.8....0.58,

initial dielectric
-THERMOCOUPLEmination
Determa ofomential
OUTER ELECTRODE
Ds 'eletric
pm n
g
b
befr
state
tacky
wURN
INSULATION
at
Test
Temperature
Strength
50%_
~~~OPPER WIRE

uteelctrdesand
TUteE
the
tube.AL

Mul

i. 85.. 200
2.45 .....240

allowance of the decrease of factor of

H Dsafety to a dangerously low value. As a
Figure 6. Insulation temperature gradients in matter of general interest, some data are
also given for decrease of dielectric
air at atmospheric pressure-asbestos sheets
strength
strength.
ntaldeec
the
1-minute
~~IONINSULAVON ~ncesar to 75 per cent of initial
DROP THROUGH
INSULATION

minteestswermaesartngt
With the insulations tested it

was

first

necessary to determine the initial dielec-

tric strength as a function of temperature,

that is, the dielectric breakdown of the
insulation the first time it was brought up
to the testing temperature. Most of
these data are based on 60-cycle 1 -minute
holding tests. However, there might be
some controversy as to whether the determination of the initial dielectric strength
nrmns
apoiaey1eercn
should be made using a 1-minute
holding
a
test.
test or
Therefore,
momentary
data were taken on both bases. The 1-

ar
failure which

may

be encountered in

practice. For many years,ution1thick

holding test has been the standard for factory acceptance tests. This factors the
thermal
effect particularly
Pee important in
nsltonLf
class B asbestos inlsulations operated in
air.

airo

Determination ofethemCriterion
Voltage for Breakdown of
Insulation Life Pieces

Knowing the average insulation thickness, the initial breakdown voltage was
calculated from Figure 5. Then the
breakdown test voltage was taken as 25,
50, or 75 per cent of the initial breakdown
voltage, depending upon which figure was
chosen as the criterion of life. Both the
1ae
-minute and momentary tests were made
at time intervals of approximately two
per cent of the anticipated life of the

Figure 8 (left). Chamber For

10

testing insulation pieces in

THICKNESS - 2(15 MI)

GRADE -COMMERCIAL

APPLICATION

inert atmosphere

IMPREGNANT
*

(0000

LAYER INSULATION

HIGH TEMPERATURE
PHENOLIC VARNISH

10000BREAKDOWN

-50%

~~~~~~~~~INITIAL
HOT
DIELECTRIC

CRITERION

OF

STRENGTH,

___

~~~~~~~~~~MINUTETEST

3:

0
Y
Q:

COOLING MEDIUM- AIR AT ATMO.5 _

~~~~~~~~~~~~~~~~SPHERIC

N,

IS
0

equilibrium had been attained on each

test piece. These were plotted then as
shown on typical curves in Figure 6.
The average insulation temperatures,
existing for each test point, were cal-

culated by averaging the corresponding

reading from the maximum to minimum

temperature curves.
It will be noted that considerable radial
gradients are indicated from the thermocouple in the tube wall to the thermocouple on the outer electrode. The point
might be raised whether these gradients
are actually in the insulation itself or
whether they might be largely in a
theoretical air film each side of the insulation. To investigate this, several test
pieces were made up with different numbers of layers of insulation. The watts
input to the heating unit was measured
and the temperature determined.
From these data, the degree temperature drop-per-mil insulation thickness was
calculated, Table I. It is seen that these
values are approximately the same without regard to number of layers, showing

gradientsgaretoinu
her finlmtdop
insulatirhowing
tananlthat only
onlsmall
surfae film
eitst
small surface
drops exsst.

Also, temperature resistivities of approxi-

mately 250 degrees centigrade per watt

per square inch per inch, for impregnated

asbestos were determined which approxi-

on the bottom being only

about 2.5 per cent more than that on the
top. In examining pieces that failed,
records werc kept as to the position of
failure. No particular pattern or trend
was noted in these records.
In the case of the fiber glass wire pieces,
the average insulation temperature was
determined by taking 25 per cent of the
difference between the tube temperature
and the outer electrode temperature and
adding this 25 per cent to the outer elec
trode temperature. That this is a proper
procedure will be clear from Figure 7 and
the following considerations.
The temperature gradients here can be
considered in three parts:
1. Gradient from the metal tube to the
copper through the insulation between the
tube and the copper.
2. Gradient through the copper wire itself,
3. Gradient from the copper wire to the
outer electrode through the insulation between the copper and the outer electrode.
It is at once evident that items 1 and 3
are equal in magnitude from symmetry,
small differences due to curvaneglecting
ture. Let us compare the thermal drop

temperature

10000C

mately check the values of similar insula-

- 50

tion.3

these test
pieces. Table II shows result of tests
with thermocouples placed around tube
and outer electrodes. It is seen that
these differences are small; the maximum

NI

AS

12

Run

Number

O'Clock O'Clock O'Clock

Position

_0-

xVARNISHED

CAMBRICE

9
PAPER

O'Clock

1587.1
139.
185.9
.8
1.232..2.87
26.1
.... 23789...
3. 3...261..234.4

1948, VOLUME 67

- --_

the temperature of a point halfway from

________I
I

--- 50 *. CRITERION_'/2 KV/SEC.

50 7 CRITERION I MIN.

ICC L

-~FCAMBRIC

3
---

1I I

~~~~~~~~~~~ASBESTOS
S, KRAFT
PAPRHETSAN

SHEET.AND

Figure 9. Summary of

[ABSO-KAT-FIBEIR

life characteristics of

insulations in air at atmospheric pressure

Stewart,

VARNISH

GLASS YARN ARE

KRAFT
IMPREGNATED WITH HIG
PAPER
TEMPERATURE PHENOLIC \0 I I
100 140 180 220 260 300 340
AVERAGE INSULATION TEMPERATURE ( C)
FIBER

Number Number Number Number

1
2
3
4

2.... 18553

3.

through item 2 compared with the sum of

those through items 1 and 3.
The thermal resistivity of copper is
0.1125 degree centigrade per watt per
cubic inch, while that of fiber glass is
.
g
approximatcly 250 degrees centigrade per
The thermal drop through the copper
can be neglected since its thermal resistance is roughly 1/1,000 of that through
the fiber glass for the thicknesses involved.
Since we are applying the dielectric test
between the outer electrode and the wire,
we are interested in the average temperature of the outer portion only; that is,
that of item 3. Again from symmetry,
the average temperature of this region is

SEESTOS
SHEETS

--BA0

INOTE:

I........155.2.... .158.0.... 159.0....156.7

sheets

FIBER GLASS YARN

BLACK
~~~~~~~~

Insulation

100
14
180 220 260 300 340
AVERAGE INSULATION TEMPERATURE ('C)
Figure 10. Life characteristics-asbestos

l|

-r

U 1000

10

/CRITERION- MINUTE

10000

on

Table II. Temperature on Tube Under

-75'/. CRITERION - ( MINUTE

There remains the circumferential

temperature gradients

---

= ---5o%CRITERION- I/2 KV/SEC

lWhitman-Transformer Insulation

GLASS YARN
T

~~~~~~~~~~~~~~~~~~~~~~~~PRESSURE
lO

. \

l~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~10
0

-PP

TEMPERATURE PHENOLIC VARNISH

0 130
160 200 240 2B 320

WITH HIGH

DEGREES CENTIGRADE
(RECIPROCAL ABSOLUTE TEMPERATURE SCALE)

Figure 11. Summary of life characteristics of

insulations in air at atmospheric pressure

1603

1000

T000

THICKNESS - 2 (IS MIL)

APPLICATION - LAYER INSULATION
GRADE - COMMERCIAL

HICKNESS APPLICATION
GRADE

IMPREGNANT- HI'GH TEMPERATURE PHENOLIC

10000

75 .1. OF INITIAL HOT

DIELECTRIC
STRENGTH,
10000
MINUTE TEST
~~~~~I
-

00
1000(

z~~~~~~~~~AMSPEI

co

CL

1000

co

HIGH TEMPERATURE
~~~~~~~~~~~~VARNISH

RADW

PHENOLIC'

IMPREGNANT

HIGH TEMPERATURE PHENOLIC

VARNISH

0/OFBAKWNRIRON5%FIIILHT
RTRO-D~.O
RADW
RTRO
0,O NTA
O
DIELECTRIC STRENGT
10000
HOT DIELECTRIC STRENGTH,
RVERDEI~K/S EC.

~~~~~~~~~~~~~~~~~INITIAL

IE-COOLING
z

RAEO
'/2
KS/SEC.
0COOLING MEDIUM -AIR AT
_
_~~~~0ATMOSPHERIC
PRESSURE

~~~~~~~~~~PRSUE
o
__
cC

20OMILS ON RECTANGULAR COPPER

CONDUCTOR
APPLICATION - TURN INSULATION
GRADE - CONTINUOUS FILAMENT

THICKNESS

EADWCRTRO

COOLING MEDIUM -AIR AT

000

(IS MILl
LAYER INSULATION

COMMERCIAL

~~~~~~~~IMPREGNANT

VARNISH

VARNISH

BREAKDOWN CRITERION

2
-

MEDIUM-

gV_1__

~~~~~~~~~~~1000

CC

AIR
PRESSURE

AT ATMOSPHERIC

00

~~~~~~~~~~~~~~~0

ra

cr_

10010

0-I

_120 130 140 160

240
180 200
280
DEGREES CENTIGRADE
(RECIPROCAL ABSOLUTE TEMPERATURE SCALE)

120 130 140 160 180 200

240
280
DEGREES CENTIGRADE
(RECIPROCAL ABSOLUTE TEMPERATURE SCALE)

Figure

characteristics-asbestos
sheets

1 2. Life

the copper wire to the outer electrode,

which is 25- per cent of the effective thermal distance and hence 25 per cent of the
temperature drop from outer electrode to
tube surface. Again,, we are neglecting
the correction for curvature, whic'h would
be negligible,
The voltage supply to the heating unit
in all cases was maintained at a uniform
value by means of voltage stabilizer units
so that heating was essentially constant.
The ambient temperature was closely
maintained by auxiliary heat and exhaust
fans, both thermostatically controlled.
The variation of the temperature of the
insulation under test was not more than
100000 -

HCNSS
GRADE

1 ML

THICKNESS
(15
MIL)2

APPLICATION

LAYER

Figure 16. Life characteristics-fiber glass

five degrees from the average value over

any 24-hour period, and for practically all
the time the variation was less than two

dielectric test's and for supplying heating

14. Life

degrees.

Tests Made in Inert Gas

Most of the data in this paper were obtamned with the samples exposed to free
air at atmospheric pressure.
In order to see the effect of oxygen on
the rate of deterioration, some units were
sealed in a chamber in pure nitrogen.
The units were constructed in the same
manner as all others and electrodes
brought out of the sealed chamber for

000

___________O__________
20 MILS ON RECTANGULAR

~~THICKNESS

COMMERCIAL

1MPREGNANT

VARNISH

- HIGH TEMP. PHENOLIC VARNISH

BREAKDOWN CRITERION - SO./. OF INITIAL HOT
DIELECTRIC STRENGTH,
MINUTE TEST
MEDIUM - AIR AT ATMOSPHERIC

10000

~~~COOLING

STRENGTH,

MINUTE TEST

3::-

COPPER CONDUCTOR
APPLICATION - TURN INSULATION
-GRADE - CONTINUOUS FILAMENT

INSULATION

BREAKDOWN. CRITERION - 50%. OF

INITIAL
HOT
DIELECTRIC

COOLING MEDIUM-AIR AT
~~~~~~~ATM

_
_
240
280
120 130 140 160 180 200
DEGREES CENTIGRADE
(RECIPROCAL ABSOLUTE TEMERATURE SCALE)

characteristics-asbestos
sheets

Figure

IMPREGANT IGH TEPERATUE PHENLIC

10000

*IC--

PRESSUR

yarn

current.
Tmeaue of all parts of the
unit were determined by thermocouples
as in previous tests. The gas pressure
was set at five pounds gauge to i-nsure the
purity of the nitrogen gas. Also, this

would be a possible operating condition

for a sealed dry-type transformer. Constrtiction of this chamber is shown in
Figure 8.
Results to date indicate that the life of
impregnated asbestos operated in this
manner is considerably lengthened, at
least for temperatures above 200 degrees
centigrade. No failuires in the insulation
IOOQOC

TIKES-17ML

-APPLICATION - LAYER INSULATION

GRADE - G. E. ELECTRICAL
IMPREGNANT- NO ADDITIONAL
-BREAKDOWN CRITERION - 50% OF INITIAL HOT
DIELECTRIC STRENGTH,
TEST
MINUTE
100COIGMDU
I
TAMS

PRESSUREEDIMPHEARCT PREOSSUR
PHRI_PESUR
___

OSPHERIC

HoooH-C H0

____
12

6
0
4
8
DEGREES CENTIRD
(REIPOCL BSOUT
TMPRAURESCLE

Fiur 1. iF

carctrstcsasesos

_K7

_~~~~~~~~~~~~~N
iitt _

2 101010820
20
201011 2 3 4
6
0
4
8
DERE
ETIRDERESCNIRD
(ECIROALABOLTE EMERTUE CAL)
REIPOCA ASOUT TMPEATRESCLE

Fiur

15

Lfechrateisic-fbr

las

igre1 .

if

haacerstcsblckyan

00000-

THICKNESS

in a gas medium, see Table III. '

operate
4. Extrapolation of these data

1(7 MIL)

prt

APPLICATION - LAYER INSULATION

on

GRADE-GNE. ELECTRICAL

GRADE

BREAKDOWN CRITERION - 50% OF INITIAL HOT

10000

DIELECTRIC STRENGTH,
RATE OF RISE Y2 KV

COOLING MEDIUM-AIR AT ATMOSPHERICPRESSURE

cffl

F e

1,

<

THICKNESS
HCNS

APPLICATION

~~~~~~~~~~~~~~~GRADE

2 (44ML
MIL)
-

LAYER INSULATION

ABSORBENT

PRGNANEAESOREENT

G.E. ELECTRICAL

class A material to 105 degrees centigrade

continuous operation shows that dielectric
strength is reduced to one-half of its initial

value in approximately two years, where

insulations operate in a gas medium, see

~~~Table III.
5. The so-called degree rule (degrees c

l
VARNISH
CRITERION- 504/. OF INITIAL HOT
10000 BREAKDOWN
COOLING MEDIUMM- AIR AT ATMOSPHERIC

PRESSURE

0_
t 1000

increase in temperature to reduce life 50

____
per cent) of insulations operated in a gas D
_ _ _ j0
medium changes markedly depending
=
__
X
--tt - ___
upon the class of insulation and its operat-
- -- _ -ing temperature.
loo __=__
0 _
0 0O
6. Degree rule for class A insulations5
o
O

5 9000in a gas medium is indicated as halving

_<l_________ =___ ___
the insulation life for each approximately
10 degrees centigrade increase in the range
100 110 120 130 140 160
200
240 280
of 105 to 150 degrees centigrade, Figure
200
240 280
0 110 120 130 140 160
DEGREES CENTIGRADE
CENTIGRADE
D0
DEGREES
20
(RECIPROCAL ABSOLUTE TEMPERATURE SCALE)
(RECIPROCAL ABSOLUTE TEMPERATURE SCALE)
7. Degree rule for class B insulations
Figure 18. Life characteristics-black yarn- in a gas medium is indicated as halving Figure 19. Life characteristics-kraft paper
ished cambric sheets
sheets
the life for each approximately 13 degree
centigrade increase in the range of 130 to
hours (3.4 years) is obtained considering
have yet occurred in the elapsed testing 200 degrees centigrade, Figure 20.
time which is roughly three times as long
8. It is interesting to note that in asbestos and the inverse absolute temas that for similar insulation operating in general, the life of class B materials is ten perature5 extrapolation, which appears to
free air at the same temperature. This times that of class A materials operated be the more accurate method.
would seem to allow an increase of at in a gas medium at the same temperature,
Dry-type transformers are seldom
least 25 degrees centigrade in hot-spot see Figures 9 and 11.
loaded to capacity for more than 8 out of
9. If a life criterion at 75 per cent of 24 hours and so do not operate at ultimate
temperature for class B insulation, operated in an inert atmosphere, with normal initial strength is used instead of 50 per temperature for more than about 5 out of
life. XVhether the relation holds for lower cent, a further shortening of life of about 24 hours, due to inherent thermal capactemperatures is not yet known as not 10 per cent will result, see Table III.
ity. Since these data are obtained on
the basis of continuous operation, it is,
enough data are available to determine
the "degree rule." This relation may or Evaluation of Data in Terms of
therefore, necessary to introduce a facmay not hold for other insulations, alDry-Type Transformer Life
tor which evaluates these data in terms of
though some improvement is probable.
life where a transformer does not operate
Extrapolation to 130 degrees centi- at maximum temperature continuously.
grade as shown in Table III indicates that Based on the foregoing assumption, dryResults
the initial dielectric strength is decreased type transformer life ig terms of these
1. Figures 9 to 19 inclusive, give the to half value for class B insulations in 3 data can be assumed to be increased 24/5
life characteristics of the variouls insula- to 41/2 years of continuous operation. or 4.8 times. This is equivalent to saying
tions investigated in this research. It is to The variation in years is due to the indi- that a dry-type transformer operating on
be noted that in all cases these are plotted vidual material and the method of extra- this load cycle and attaining a hot-spot
with the hours to breakdown on the polation employed. A value of 30,000 temperature of 130 degrees centigrade will
logarithmic y axis, but that the average
insulation temperature is plotted on the
uniform x axis with an evenly divided
Table Ill. Life of Material Operated in Air at Atmospheric Pressure
degree-centigrade scale, Figures 9 and 10;
' tem-'
~~~~~~~~~~BredkdownVoltdge Used aS Life Criterion
and also with a reciprocal absolute
perature scale,4 Figures 11 to 19 inclusive.
The latter gave straight-line characterisInitial
in
ease
extrapolaStrength
Using Reciprocal of
Using Average
allowing
greater
ties,
0

(D

tic
tion.

Breakdown
Criterion,

2. Summary of all life characteristics

is given in Figure 9 and Figure 11 plotted

as a function of temperature in degrees

centigrade, and reciprocal absolute temperature degrees centigrade, respectively.
3. Extrapolation of these data on class
B material to 130 degrees centigrade con-

strength is reduced to one-half of its initial

vTalue in 3 to 41/s years, where insulations

1948, VOLUME 67

Type of voltage

Testt.

Duration of Test

Absolute Temperature
Scale

Per Cent
1

1/2 kv

Minute Per sec

Holding Rate

Insulation Temperature
Scale

Yas

1/2 kv

Minute Per sec

Holdin Horate

ar

AseiZ
Varnished cambric at lOaC .50
.......
.18,500.. .19,000..2.1.16,000.. .16,500..1.8
at
.31,000. 3.4.26,000. .25,002.

Kasbetospe 1305C.50.30,000.

Asbestos at 13000
75 .27,000 ..3.1.21,000.2.
.......
24
Glassyarnat13o0C .0.
.25,000
......
......
040,000 .4..45
..
2.8
_________________________________________

Stewart, Whitman-Transformer Insulation

1605

l~~~~~~

,20

ASBESTOS

IMINUTE

~~

w10

8 VARNISHED
BLACK
CAMBRIC

l00

40X
TS__

ES

KLASBESTOS
'2 ISECZ,15
~~~~~~~~SHEETS

VARNISHED
IBLACK
CAMBRIC 1/2 KV/SEC
MINUTE

& 50%X
75e/J
MINUTE

_;_
\
\
o_15
~~~~~~~~~~~~~~~~~~~~~0

2
z

_ LIF
-L
120

centigrade is 57,000 hours (6.5 years) for

continuous operation. For the load cycle
of 8 hours (5 hours effective) operation out
of 24 hours, the expected life at 120 degrees
centigrade becomes 24/5 X 6.5 years=
31.2 years. Then, assuming that the
transformer operates one-half the time at
the lower ambient, which results in 120
degrees centigrade temperature, and the
remainder of the time at 10 degree higher
ambient, resulting in 130 degrees centigrade temperature, the expected life becomes

= 21.4 years

130 degrees centigrade.

The deterioration of class B insulation
for overload conditions for various periods
has been calculated on the basis of the
following criteria and is shown in Figure
21.
r
n
3 e
d
i
1
when operated
1. End of life
years centigrade.
at as
1303.4
degrees
continuously
2. Deterioration rate, incremental degrees

to halve life, at temperatures in excess of 130

minute duration. In this investigation,

the results in termns of hours of operation
are substantially the same for either
momentary or 1-minute applications of

24

Figure 21. Loss of life in air-asbestos sheets

with high-temperature phenolic
varnish

proportional to the reciprocal of the

Conclusions

For the condition where the transformer

operates one-half at each temperature and
for the previously assumed loading cycle,
the expected life is

has been raised where tests are of 1-

VOltage.

3. These data support the chemical

/ 1 \=3.63 years
A:) l 1 2 t-)+ l 12 t-) jdeterioration theory4 that the logarithm
of tme roach paticlarpercntae o
This is one-sixth of the estimated life at the dielectric strength of insulation is

1606

/1\

130 140 150 160 10 180 190 200

TEMPERATURE IN DEGREES CENTIGRADE

impregnated

This is a useful guide to assess the injury toinsulation operated atcaetemperaturein excessof 130degrees centigrade.
Data from Table III and Figure 1
indicate a 30 per cent or 5-degree advantage for glass yarn over commercial grades
of asbestos. This is undoubtedly due to
contaminants in the asbestos and can be
circumvented by the use of refined grades
of asbestos or Terratex.6

0.39 years.

1.05 years.
160 degrees centigrade-5,200 hours-

,\|

LOSS OF LIFE BASED ON:

1. 3.4 YEAR LiFE AT 130 DEGREES CENTIGRADE.
2. CONSTANTLY CHANGING DEGREE RULE (FROM
GRAPHS WITH RECIPRICAL DEGREE KELVIN TEMP-

degrees centigrade as on Figure 20.

1. A new method of determining the

life characteristic of insulations operated
in gaseous mediums has been developed.
In this method, failure voltage at operating temperature expressed as a percentage
of the initial breakdown voltage has been
used as a criterion of the length of life.
The results are self-consistent and constitute a valuable and accurate tool,
yielding results in terms of voltage
strength which is of major importance in
electric apparatus.
2. In voltage testing to breakdown,
the question of effect of corona on life

This is a reasonable situation and parallels

experience in the field with liquid-filled
transformers. It is interesting to note
that if this same class B dry-type transformer is designed for a 160 degrees centigrade hot-spot temperature with the
same 10 degrees centigrade ambient
fluctuation, its life for continuous operation from Figure 13 is as follows:
150 degrees centigrade-9,200 hours

-_

SF

300

Figure 20. Variance of degree rule with temperature

Insulation in air at atmospheric pressure (Derived from Figures 12
to 19 inclusive)
Asbestos and krdft paper sheets, and fiber glass yarns are impregnated with high temperature phenolic vdrnish

120 degrees
o3lifeat
hot-spFrottemperaure
degree
life at 120
grade. From Figure 13,

__

.8

280
240
260
220
200
140
120
1I0 180
AVERAGE INSULATION TEMPERATURE IN DEGREES CENTIGRADE

have expected life of (4.8X3.4)=16.3

y-ears. Moreover, maximum ambient
conditions would seldom exist for more
than 50 per cent of the time. This would
also tend to increase the life expectancy
since insulation deteriorates at a lesser
rate at lower temperatures. A 10 degree
woud reult
redutionin
in abien
result inn aa
ambient would
reduction

MNT

KRAFT PAPER

ll
60

MINUTE

Ic

SHEETSI_

81

FIBER GLASS YARN

SHEETS
ASBESTOS
l

[1

30

Stewart, Whitman-Transformer Insulation

absolute temperature.

4. Based on our data, it appears unwise to consider continuous operating

hot-spot temperatures in excess of 130
degrees centigrade for class B insulations
in use at the present time.
5. Considering the normal operating
temperatures encountered by dry-type
transformers due to normal load cycles
and ambient fluctuations, it has been
shown that such a transformer operated
at not over 130 degrees centigrade hotspot temperature will have a life comparable with the normal liquid-filled
transformer.

References
1. ASTM STANDARDS ON ELECTRICAL INSULATION
MATIERIAL D-229-43. American Society for Testing Materials (Philadelphia, Pa.), Paragraph 33-b.
2.

OF

ON TEST FOR TIoCKNESS

ASTM
PAPER STANDARDS.
PRODUCTS. American
Society for

Testing Materials (Philadelphia, Pa.), Part III-B

Section D-645-43 Method B.
3. TRANSFORMER ENGDNEERDNG (book)-Blume.
John Wiley and Sons, New York, N. Y., 1938,
page

270.

4. ELECTRICAL INSULATION DETERIORATION

TREATED AS A CHEMICAL RATIE PEENOMENON.
Thomas W. Dakin. AIEE TRANSACTIONS, volume

67, part I, 1948, pages 113-18.

,. TEMPERATURE:-AGING TESTS ON CLASS-A-

INSULATE:D FRACTIONAL-HORSEPOWER MOTOR

STATOS J. A. Scott,(B.EH.TThomsoBn. ELECTRI
61, July 1942, pages 499-501.
6. TERRATEX, A THXIN FLE:XIBLE3 INORGANIC
T. R. Walters. AIEE TRANSAC~~~~~~~~~INSULATION,
TOS oue6,pr ,14,pgs137
TOS oue6,pr ,14,pgs137
TRANSF ORM ER WINDINS UH.Rc SteINart,Y-TYC.

volme
WhtRanSACION)E
763-68.

63,

October

1944,

pages

AIEE TRANSACTIONS

Discussion
V. M. Montsinger (General Electric Company, Pittsfield, Mass.): When a new insulating material is introduced on largescale production there are two general
methods open for the selection of the maximum or limiting hottest spot temperature
of the insulation. One method is to select a
temperature limit based on available laboratory data, which may be exceedingly
limited, and use this limit in designing

ltransformed,sand pu thisalimit
invel dearsi
that

the temperature
perience will show
limit is safe. The second method is to base
the temperature limit on the result of extensive laboratory aging tests on the insu-

lating material,
The experience method of determining the
limiting insulation temperature for a reasonable length of time is exceedingly difficult
Of application, and requires a long time-20
years or more. Carefully kept records of
loading and ambient temperatures covering

many installations are needed as well as an

exceedingly high degree of skill and ability
in the analysis of the records.
The laboratory test method is also difficult of application. It requires that some
characteristic of the insulation, mechanical
or electrical, be selected as the basis of comparison of the effects of various temperatures and time. It also requires that some
arbitrary value of the selected characteristic, in relation to its initial value, be chosen
as the end point of the useful life of the insulation. It needs, too, the exercise of sound
engineering judgment tempered by experience to translate the test results into design
limits for the industry.
The use of class B insulation is, of course,
not new. AIEE Standards have defined
class B insulation and for many years the
maximum temperature has been set at 130
degrees centigrade. Class B insulation has
been used in rotating machinery for many
years, but its use in moderate sized dry-type
power transformers started at a fairly recent
date, some eight or ten years ago.
The question of whether 130 degrees
centigrade hot-spot temperature was the
correct value for dry-type transformers was
debated for several years in the AIEE
transformer subcommittee (now the transformer committee) without getting anywhere. To settle this question it was decided by the transformer committee to start
some co-operative aging tests in various
laboratories. A working group, who had
carried out co-operative aging of class A insulation, was requested to undertake this
job of making laboratory tests on classes B
and H insulation. Today four laboratories,
General Electric, Westinghouse, Allis-Chalmers, and Dow-Corning, are co-operating in
the making of these tests.
As previously stated, the two available
methods for determining the maximum
temperature limit for a new insulation are
laboratory tests and experience in the operation of transformers. To obtain the final

1948, VOLUME 67

answer for classes B and H insulations will

probably require results obtained by both

niethods.
The very complete data presented in the
paper by Stewart and Whitman are, of
course, in the laboratory class. These tests
were started approximately 11/2 years before
the AIEE working group was requested to
start its co-operative aging tests on classes
B and H insulations.
I feel that exhaustive laboratory tests,
similar to these tests or to the test that will
be finally agreed upon by the working group,
are absolutely necessary. The authors are
to be highly commended for presenting the
very complete data in their paper. The
results should serve as a "bench mark" for
many years to come.
As a final check on their work, and on the
work that has been carried on in the Westinghouse Laboratory at East Pittsburgh,
the working group is planning on making
further pilot tests to decide on a final
method for evaluating the effect of temperature on these insulations. When this
point is settled the main program of tests

T. R. Walters (General Electric Company,

Pittsfield, Mass.): The authors have presented an interesting addition to the relatively meager literature on aging characteristics of class B insulations.
For the past several years we have been
carrying out, in the laboratory at Pittsfield,
aging tests on various class B insulations
independently of the tests carried out by
Stewart and Whitman. Our tests were
carried out in circulating air ovens at temperatures of 150, 175, and 200 degrees centigrade. Reference to some of the earlier
data at 175 degrees centigrade was given in a
paper by T. R. Walters.i
Although various criteria have been used
for determining the end of the useful life of
insulation, we believe that one important
factor in the life of dry-type apparatus is
humidity. As long as the apparatus is in
service, it will remain fairly dry. However,
if it is shut down for weekends or other extended periods, the insulation depends on
its varnish treatment for moisture protection. Accordingly, our laboratory tests
were set up so as to periodically measure
power factor of the samples after 24-hours
exposure to 90 per cent relative humidity at
90 degrees Fahrenheit, as a check on the
effect of high temperature aging. A "runaway" power factor condition at high
humidity was taken as the end-point of insulation life.
The advantages of this method of judging
end-point are that the break in the power
factor versus time curve is relatively sharp;
power factor values are not affected to any
great extent by differences in the size of
samples; and small imperfections in the
samples are averaged out.
Comparing our data with that shown by
Stewart and Whitman, we find that we are
in general agreement, even though our tests
were carried out quite independently, using

Stewart, Whitman-Transformer Insulation

and a different
procedure
of useful life. The same
criteria for the end
insulations and high temperature varnish
were used. The authors data indicate a
"degree rule" of 13 degrees centigrade for
this class of insulation. Our results showed
a slightly higher "degree rule," 14 degrees
centigrade or higher, with a somewhat
shorter life at any given test temperature.
The shorter life may be partly explained by
the fact that our tests were run in an oven,
where the samples were at a uniform temperature throughout, while the authors
simulated service conditions where there
was a temperature drop through the insulation.
In any event, our data tends to corroborate Stewart and Whitman's conclusion that
130 degrees centigrade is about the maximum hot spot temperature that can be permitted in dry-type class B insulated apparatus operated in free air, if the usual useful
life is to be expected in service.
a different test

REFERENCE

1. See reference 6 of the paper.

H. C. Stewart and L. C. Whitman: T. R.

Walters has indicated that humidity may
have a bearing on the life of insulation-s
operating in free air. We purposely omitted
the humidity angle since we were interested
in the maximum life of insulating materials.
It is possible that apparatus may be operated continuously, either with or without
load, in which case there will be sufficient
heat to prevent condensation and water
absorption. Under such conditions, humidity will have little effect on insulation life.
Should there be heating and cooling periods
due to shutdown, then humidity can be an
unfavorable factor. Both conditions should
be considered eventually, but it is more important to consider the most favorable condition when consideration is directed to the
increase of the temperature limit for class B
insulation. It is gratifying to find that the
two methods result in general agreement as
to life of this type of material. It would
appear that dielectric tests are sufficiently
searching and that the complication of
humidity may not be justified. The particular advantage of the method we proposed lies in the fact that life is evaluated in
terms of the original dielectric strength and
so is easier to interpret than resistance and
power-factor tests.
V. M. Montsinger has commented on the
difficulties encountered in setting up temperature limits for insulation. We have
attempted to show that the established 130
degrees centigrade hot-spot temperature
should not be exceeded in dry-type transformers.
Further information may substantiate the
use of higher temperatures for class B insulations in inert atmosphere than is permissible
when they are exposed to the oxygen of air.
We hope that the data presented here
will be of assistance to the AJEE wrorking
groups in their evaluation of the effect of
temperature on class B insulation.

1607